EP3778471A1 - Herstellungsverfahren von siliciumnanodrähten auf kohlenstoffbasierten pulvern zur verwendung in batterien - Google Patents

Herstellungsverfahren von siliciumnanodrähten auf kohlenstoffbasierten pulvern zur verwendung in batterien Download PDF

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EP3778471A1
EP3778471A1 EP20195843.6A EP20195843A EP3778471A1 EP 3778471 A1 EP3778471 A1 EP 3778471A1 EP 20195843 A EP20195843 A EP 20195843A EP 3778471 A1 EP3778471 A1 EP 3778471A1
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Prior art keywords
carbon
nanowires
tumbler
silicon
based substrate
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EP20195843.6A
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English (en)
French (fr)
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EP3778471B1 (de
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Yimin Zhu
Vincent Pluvinage
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OneD Material Inc
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OneD Material Inc
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    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J3/00—Processes of utilising sub-atmospheric or super-atmospheric pressure to effect chemical or physical change of matter; Apparatus therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J15/00—Chemical processes in general for reacting gaseous media with non-particulate solids, e.g. sheet material; Apparatus specially adapted therefor
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J19/00—Chemical, physical or physico-chemical processes in general; Their relevant apparatus
    • B01J19/28—Moving reactors, e.g. rotary drums
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
    • B01J4/00—Feed or outlet devices; Feed or outlet control devices
    • B01J4/001—Feed or outlet devices as such, e.g. feeding tubes
    • B01J4/007—Feed or outlet devices as such, e.g. feeding tubes provided with moving parts
    • C—CHEMISTRY; METALLURGY
    • C01—INORGANIC CHEMISTRY
    • C01B—NON-METALLIC ELEMENTS; COMPOUNDS THEREOF; METALLOIDS OR COMPOUNDS THEREOF NOT COVERED BY SUBCLASS C01C
    • C01B33/00—Silicon; Compounds thereof
    • C01B33/02—Silicon
    • C01B33/021—Preparation
    • C01B33/023—Preparation by reduction of silica or free silica-containing material
    • C01B33/025—Preparation by reduction of silica or free silica-containing material with carbon or a solid carbonaceous material, i.e. carbo-thermal process
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • C22C38/02—Ferrous alloys, e.g. steel alloys containing silicon
    • C—CHEMISTRY; METALLURGY
    • C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
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    • C23C16/22—Chemical coating by decomposition of gaseous compounds, without leaving reaction products of surface material in the coating, i.e. chemical vapour deposition [CVD] processes characterised by the deposition of inorganic material, other than metallic material
    • C23C16/24—Deposition of silicon only
    • C—CHEMISTRY; METALLURGY
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    • C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
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    • C23C16/4417—Methods specially adapted for coating powder
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    • C23C16/4418—Methods for making free-standing articles
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    • C23C16/45563—Gas nozzles
    • C23C16/45578—Elongated nozzles, tubes with holes
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    • H—ELECTRICITY
    • H01—ELECTRIC ELEMENTS
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    • H01J37/32403—Treating multiple sides of workpieces, e.g. 3D workpieces
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Definitions

  • Embodiments of the present application relate generally to manufacturing apparatus, systems and methods of growing silicon (Si) nanowires on carbon based substrates, such as on the particles of graphite powders, to economically make silicon-carbon hybrid active materials to be used for example in lithium ion batteries. More specifically, embodiments of the present application relate to inventive tumbler reactors and chemical vapor deposition (CVD) systems and methods for growing silicon nanowires on carbon based substrates at large-scale quantities to meet the growing demand for active materials for the battery industry.
  • Si silicon
  • CVD chemical vapor deposition
  • LIBs Lithium ion batteries
  • LIBs are one of the most promising areas for further advancement.
  • LIBs generally are comprised of an anode, a cathode, a separator material separating the cathode and the anode, and an electrolyte.
  • the anode of most commercially available LIBs generally includes a copper foil current collector coated with a mixture of graphite powder, a binder material and/or conductive additives.
  • the cathode of most commercially available LIBs generally includes an aluminum foil current collector coated with a lithium transition metal oxide based cathode material.
  • Traditional LIB anodes include intercalation-based active materials, such as natural or synthetic graphites, which have limited charge capacity and are falling short of the rising market demand for higher energy density (volumetric or gravimetric), higher power density, greater cycling life, longer battery lifespan, faster charging rates, larger temperature charging range or operating range, lesser swelling, and other key performance metrics.
  • intercalation-based active materials such as natural or synthetic graphites, which have limited charge capacity and are falling short of the rising market demand for higher energy density (volumetric or gravimetric), higher power density, greater cycling life, longer battery lifespan, faster charging rates, larger temperature charging range or operating range, lesser swelling, and other key performance metrics.
  • the ratio of Li/Si ranges from 1.71 for the alloy phase Li 12 Si 7 (with a theoretical capacity of 1636 mAh/g) to 3.75 for the alloy phase Li 15 Si 4 (with a theoretical capacity of 3579 mAh/g).
  • the richest alloy phase Li 22 Si 5 has a ratio of 4.4 and a theoretical capacity of 4,200 mAh/g, but it is typically not reached in practical applications.
  • Si has slightly higher voltage plateau than that of graphite, so it has attractive safety characteristics.
  • Si is an abundant and inexpensive material, and lithiated Si is more stable in typical lithium-ion battery electrolytes than lithiated graphite.
  • active materials based on Si nanowires grown and/or attached onto carbon based substrate can be produced in large quantities at attractive costs and address prior limitations of other silicon comprising active anode materials for LIBs.
  • Nanowires are typically described as "one-dimensional nanostructures" because of very small radius and high length/radius aspect ratio.
  • the nanowires can have an average diameter less than about 200 nm, e.g., between about 5 nm and about 100 nm, e.g., between 20 nm and about 50 nm.
  • Si nanowires exhibit aspect ratios (length-to-width ratio) of 5, 10 or 15 or more, 25 or more, 50 or more, or even greater than 100.
  • Si nanowires present unique physical, chemical and electrical properties making them suitable to overcome many of the side effects produced by other forms of silicon-comprising materials when they are used as anode active material in LIBs.
  • the high surface curvature (i.e. small diameter) of the Si-nanowires provides a lower energy barrier for lithium insertion and allows for an easier release of mechanical stress due to lithium ions disrupting the silicon structure.
  • the nanowire's crystalline structure typically becomes amorphous and the nanowires become more flexible, adjusting to volume changes without exhibiting cracks.
  • each nanowire When silicon nanowires are grown directly onto the surface of graphite particles, each nanowire is free to expand and contract while remaining attached at one end, where the nanowire is attached to and makes electrical contact with the surface of the graphite particle.
  • the alloy formed by the combination of lithium and silicon atoms greatly increases conductivity, enabling the efficient transport of electrons along each nanowire to and from the graphitic substrate.
  • the many nanowires attached to the surface of each particle of graphite can expand and contract within the pores between graphite particles while remaining electrically connected at their respective attached points to the carbon-based substrate.
  • the graphite particles are in electrical contact with one another, in a porous structure containing a binder and a conductive additive.
  • the porous anode layer comprises of adjacent graphite particles (each particle connected to a large number of Si nanowires), enabling both the flow of lithium-ions thru the electrolyte to and from the nanowires and the flow of electrons to and from the nanowires thru the graphite particles and eventually to the current collector foil of the anode electrode. Because each nanowire is attached at one end to the graphite substrate, there is no need for the nanowires to make direct electrical contact with one another: the electrons follow an electrical path from each nanowire thru its attachment on the surface of the graphite particle, and thru the graphite particles to the electrode current collector. Thus, each nanowire is free to flex and change shape during cycling without affecting the electrical connectivity or the mechanical integrity of the anode composite layer.
  • the anodes comprise a small percentage of silicon additive, such as silicon oxide (SiO x ) particles mixed in with the active material graphite powder.
  • Si nanowires composites suitable as anode material for LIBs has been constrained by production methods capable of producing less than a metric ton per year, with low yield and high unit cost.
  • the present invention provides for the fabrication of industrial quantities of material comprising silicon nanowires attached at one end to the surface of graphite particles, within precise specifications and at an acceptable cost following an efficient and automated process.
  • Embodiments of the present invention relate generally to manufacturing apparatus, systems and methods of making silicon (Si) nanowires suitable for use as anode active material in lithium ion batteries.
  • manufacturing apparatus, systems and methods are provided to grow Si nanowires on graphite or carbon powders using chemical vapor deposition (CVD) processes to produce at industrial scale.
  • CVD chemical vapor deposition
  • embodiments of the present application provide an inventive tumbler reactor and chemical vapor deposition (CVD) system configured to grow silicon nanowires on carbon-based substrate, such as graphite particles or powder, in scaled up quantities.
  • CVD chemical vapor deposition
  • the apparatus and methods of the present application may be used to provide industrial scale anode materials for the LIBs industry.
  • tumbler reactor and tumbler are used interchangeably.
  • a method of manufacturing silicon nanowires in which silicon nanowires are grown onto carbon based substrate by chemical vapor deposition of a silicon containing precursor to form a carbon-based silicon nanowire composite, wherein conversion of the silicon containing precursor to the silicon nanowires is at least 30%. In other embodiments the conversion is at least 50%, or preferably at least 70%, , or preferably at least 90%, or even greater than 98%, and wherein at least 1 kg of the composite of silicon nanowires and carbon-based substrate can be produced per batch, preferably in batches greater than 10 Kg each, or even greater than 20 Kg each, and wherein the mass of silicon is at least 4 wt.
  • carbon-based silicon nanowire composite is also sometimes referred to as “carbon-based silicon nanowire composite powder” or simply a “carbon-silicon composite,” and that the terms are used interchangeably.
  • the carbon-based silicon nanowire composite is further processed to form an anode, by coating an electrode foil according to techniques known in the art.
  • the anode is further combined with a cathode, a separator and an electrolyte to form a lithium ion battery.
  • a Low-Pressure CVD system configured, modified and/or adapted to provide faster cooling and heating of the CVD chamber.
  • the LPCVD system may be configured to move the furnace heating/cooling unit that heats and cools the process tube and tumbler reactor away from the chamber to increase the furnace utilization efficiency.
  • a carriage rail with wheels is provided and configured to allow the tumbler reactor to move in and out of the metal or quartz process tube.
  • the carriage rail may also be configured to support the tumbler reactor when it is heavy for large load of carbon-based silicon nanowires composite.
  • the tumbler reactor may be kept in a fixed position with respect to the furnace assembly and the heating and cooling elements may be moved along the same axis as that of the tumbler.
  • a metal process tube is used, thereby replacing a quartz process tube, to enable the loading of heavier powder material into the tumbler reactor, which enables greater Si nanowires production volume.
  • the apparatus of the present application is configured to provide carbon based-silicon nanowires composite production volume of up to hundreds or even thousands of metric tons per year. The capability to produce at such scale is a significant advantage over prior manufacturing techniques, and the greater production volume provided by the apparatus and system of the present invention will enable the widespread adoption of carbon based-silicon nanowires composite as anode materials for the battery industry.
  • the LPCVD system of the present application integrates a tumbler reactor having a rotating and mixing mechanism.
  • the rotating and mixing mechanism is coupled with a gas manifold and optionally with one or more scrapers.
  • the gas manifold may be comprised of several configurations to manage gas distribution throughout the tumbler reactor.
  • the gas manifold may be a single elongated member, or may be U-shaped, or may be a frame manifold, and the like.
  • the gas manifold may be combined with one or more scrapers.
  • the tumbler may be cylindrical and its cross section may be circular or polygonal.
  • the tumbler may consist of one of more batch chambers of similar length, or may consist of a helicoidally configured continuous chamber.
  • a rotating helix may push the substrate material forward through a sequence of one or more heating zones, reaction zones and cooling zones where the injection of reactive gases is directed toward the reaction zones where silane is converted into silicon nanowires.
  • the tumbler may be positioned horizontally, vertically or at any angle with respect to the floor onto which the furnace is located.
  • the tumbler further comprises one or more fins mounted on one or more inner walls of the tumbler reactor.
  • the fins can be of any suitable size, shape or distribution and are configured to provide control and/or distribution of the powder motion in the tumbler, particularly during injection of process gases.
  • the fins may be configured to prevent the graphite or carbon-based powder from slipping along the walls during rotation of the tumbler reactor.
  • the fins may also assist in lifting the loaded graphite powders as the tumbler reactor rotates, and optionally optimize the precursor gas and heat distribution within the reactor.
  • embodiments of the present application provide systems and methods that are adaptive to produce silicon nanowires on a variety of different types of natural or synthetic graphite particles to provide flexible and robust manufacturing.
  • the graphite particles may have a low BET (less than 5 sq. m / g) or a high BET (greater than 15 sq. m / g), and may be coated or uncoated, spherical or flaky, or any combination thereof.
  • Embodiments of the present application relate generally to manufacturing apparatus, systems and methods of making silicon (Si) nanowires suitable for use as anode active material in lithium ion batteries (LIBs).
  • manufacturing apparatus, systems and methods are provided configured to grow Si nanowires on carbon based substrate, such as graphite particles or any carbon-comprising powders, by chemical vapor deposition to produce increased production volumes.
  • Si nanowires grown and attached onto graphite as anode active material in LIBs circumvent the side effects of conventional bulk Si while preserving Si superior energy density compared to C.
  • Si nanowires grown and/or attached onto graphite can have an average diameter less than about 200 nm, e.g., between about 5 nm and about 100 nm, e.g., between 30 nm and about 50 nm.
  • Si nanowires diameters are determined by the catalyst nanoparticle size, for example, Cu2O nanoparticle size is in the range of 5nm ⁇ 200nm, Si nanowires exhibit aspect ratios (length-to-width ratio) of 5, or 10, or 15 or more, 25 or more, 50 or more, and greater than 100.
  • the Si nanowire length is determined by growth time, temperature, pressure, gas flow rate, catalyst activity and density on the graphite powder surface. When the growth process temperature, pressure, gas flow rate and catalyst/density are selected the growth time mainly controls the Si nanowire length.
  • Si nanowires may be referred to as one-dimensional (1-D) materials due to their length being much greater than their radial dimension.
  • Shape and geometry of Si nanowires facilitate a quick diffusion of lithium ions and mitigate side reactions between Si nanowires and the electrolyte when used in LIBs.
  • the structure of the Si nanowires is transformed from a substantially crystalline to a substantially amorphous structure, and thus the Si nanowires become more flexible and capable to self-organize to better occupy the available space between graphite particles more efficiently.
  • a battery manufacturer will typically set the voltage range to a smaller value than the full operating range of the battery and will set the electrical current to a smaller value than the top-rated current specified in the cell data sheet.
  • This approach allows for careful building up of the SEI layer onto each silicon nanowire during the first few lithiation cycles performed by the battery manufacturer.
  • the nanowires are protected from merging and/or fusing with adjacent nanowires, and thus can more easily flex and change shape while remaining attached at one end to the surface of graphite substrate.
  • the inventors have found that by becoming flexible and remaining free to expand and contract during each cycle after the initial SEI formation cycles, the silicon nanowires progressively adjust their shape and position along adjacent silicon nanowires attached to the same graphite particle or to neighboring graphite particles.
  • the silicon nanowires occupy a small fraction of the surface of the carbon-based substrate, for example the area where the silicon nanowires are attached represent less than 5% or even less than 1% of the surface of the graphite particle.
  • the silicon nanowires occupy a small fraction of the surface of the carbon-based substrate, for example the area where the silicon nanowires are attached represent less than 5% or even less than 1% of the surface of the graphite particle.
  • the Si nanowires attached on the graphite particles become like a sponge material that occupy the pore spaces of the graphite substrate, while significantly limiting the swelling of the electrode.
  • the mechanical and electrical integrity of the anode layer is provided by the interconnected network of graphite particles, held together with a binder and optionally a conductive additive, much like in a traditional graphite-only anode, and the sponge-like collection of silicon nanowires arranged within the pores of the graphite particles absorbs and releases the lithium ions, while enabling the flow of electrons thru the graphite particles to the current collector foil. Additionally, when the silicon is substantially amorphous and the nanowire remains intact, the conductivity of the electrons along the nanowire is excellent.
  • the inventors have found that over hundreds or even thousands of cycles, the nanowires remain attached at one end to the graphite particles and remain free to flex along their axis. Electrons can travel very quickly to and from the carbon-based porous layer which typically adheres to the copper current collector thanks to the binder.
  • This hybrid Si/C material, SEI formation process and anode layer arrangement enable LIBs to have higher energy density and handle greater power, with better capacity retention over charge-discharge cycling than traditional LIBs with graphite-only active anode material or other silicon-comprising anode materials.
  • Si-nanowires grown on graphite particles result into a powder that can be sieved and used in slurry with existing roll-to-roll battery electrode coating manufacturing equipment.
  • Si nanowires exhibit aspect ratios (length-to-width ratio) of 5, or 10 or 15 or more, 25 or more, 50 or more, and greater than 100.
  • As such Si nanowires may be referred to as one-dimensional (1-D) materials due to their length being much greater than their lateral dimension.
  • Carbon nanotubes (CNT) with Si nanoparticles on the surface are also 1-D materials and they have been described as a potential alternative to Si nanowires as anode active material in LIBs.
  • the Si nanoparticles on the CNTs have a surface-to-volume ratio which is much larger than that of the Si nanowires. This distinction causes the physical structure and unique chemical, electrical properties of Si nanowires to be substantially different (and better) than those of carbon nanotubes with Si nanoparticles when used as anode active anode material in LIBs.
  • the two structures exhibit very different properties and performance.
  • the carbon (graphite) is simply the substrate on which the nanowires are attached.
  • the Si nanowires have a surface-to-volume ratio which remain approximately constant as their length is increased (i.e. as more atoms of silicon are added), while the surface to volume ratio increases when the number of silicon nanoparticles is increased. This unique geometrical/physical property produces several benefits as described below.
  • lithium ions move from the cathode to the anode and back through the electrolyte during each charging and discharging cycle.
  • Si-nanowires are used as active anode material in a LIB, the silicon can be electrochemically very active when in direct contact with the electrolyte, producing side reactions (and by-products) which result into an SEI layer around the Si nanowires.
  • the formation of a SEI layer around the Si-nanowires during the first few cycles provides a more electrochemically passive protection, preventing further silicon-electrolyte reactions while still allowing lithium ions to diffuse through the SEI.
  • Si-nanowires Unlike the larger surface-to-volume ratio of Si nanoparticles, Si-nanowires have lower surface-to-volume ratio at equivalent Si mass. Thus, less SEI needs to be formed to passivate the surface of Si nanowires than that of silicon nanoparticles on CNTs. Hence, the electrolyte-silicon side reactions on Si-nanowires consume less electrolyte during SEI formation, produce a more stable SEI layers around the Si-nanowires, and help in retaining reversible capacity thru larger number of cycles.
  • the inventors have also discovered that lithium ions can lithiate and diffuse fast in the Si nanowires, while lithium ions also intercalate into the graphite particles.
  • both the silicon in the nanowires and the carbon in the substrate participate to the storage of lithium and the flow of electrons.
  • the ratio of lithium stored in the nanowires to the lithium stored in the graphite particles is related to the weight ratio Si/C in the composite active material. At higher Si/C ratios, a lesser fraction of the lithium is stored within the carbon structures and a greater fraction of the lithium is stored within the silicon nanostructures.
  • Si nanowires on carbon substrate are particularly valuable as materials for batteries
  • the manufacturing of Si nanowires at industrial scale has been proven to be very difficult, and has not been realized yet. Accordingly, the present application describes novel manufacturing apparatus, systems and methods of making silicon (Si) nanowires suitable for use as anode active material in lithium ion batteries at industrial scale.
  • the carbon-based substrate powders used in the tumbler reactor and system of the present application can be comprised of any one or more of: natural graphite, artificial graphite, soft carbon, hard carbon, and amorphous carbon.
  • Such carbon-based substrate powders have a Brunauer-Emmett-Teller (BET) surface area in the range of approximately 1 - 30 m 2 /g, more preferably in the range of approximately 5 - 30m 2 /g for higher Si wt. % nanowire growth, and a tap density of 0.01 - 1.5 g/cc.
  • BET Brunauer-Emmett-Teller
  • the carbon-based substrate powders of the present application can be modified by its surface coating, such as carbon coating, by decomposing organic compounds such as acetylene, methane, carbon monoxide, sugar, and polymers such as CMC, PVDF, PAA, PVA and polymer mixtures.
  • Catalyst nanoparticles such as Au or Cu or Cu 2 O and the like, are deposited on the carbon-based substrate powder surface to catalyze silane decomposition for Si nanowire growth.
  • Au catalyst has a Vapor-Liquid-Solid (VLS) nanowire growth mechanism while Cu or Cu 2 O have a Vapor-Solid-Solid (VSS) nanowire growth mechanism which enables much higher Si wt. % nanowire growth on the carbon-based substrate, as described in greater detail for example in United States published patent application nos. US 2015/0086871 and US 2010/0297502 , the disclosures of which are incorporated herein by reference in their entirety.
  • Fabrication of the Si nanowires anode material is based on the inventive industrially-sized combined fixed- and fluidized-bed reactor design and system as described herein, which allows each batch to load the graphite powder at a large scale, for example from 0.5kg, 1kg, 1.5kg, 2kg and 2.5kg up to 5kg, or 10kg or 100kg or 500kg to produce Si nanowire-graphite composite materials with larger than 4 wt.% Si.
  • a "batch" size is understood to mean the weight of silicon-carbon composite powder that is produced in a single reactor chamber during the "growing step" of the process. In a continuous process, a "batch" size is weight of the silicon-carbon composite powder produced per hour in a single processing apparatus.
  • the tumbler reactor and CVD system of the present application are highly scalable.
  • the tumbler reactor is capable of producing at least 1 kg of Si nanowires on graphite powder per batch (1 kg/batch).
  • the tumbler reactor produces at least 10 kg of Si nanowires on graphite powder per batch (10 kg/batch), or at least 100 kg of Si nanowires on graphite powder per batch (100 kg/batch).
  • the system and manufacturing method of the present application achieves utilization or conversion of the Si source material (e.g. Silane) to Si nanowires approaching 100%.
  • utilization of the Si source material is in the range of about 30 - 100%, or in the range of 30 - 99.5%, and more usually in the range of about 70 - 99.5%.
  • Si nanowires are grown in the system described herein using the following conditions: temperature of about 300 - 900 °C, silane concentration of about 5 - 100% in the process gas mixture of: SiH 4 of about 5 - 100 wt.%, He (or Ar or N 2 ) of about 0 - 50 wt.%, and H 2 of about 0 - 50 wt.%, at a growth time in the range of about 10 - 500 minutes.
  • the aforementioned conditions and tumbler rotation are preferably controlled by computer with automatic software for the production.
  • embodiments of the tumbler reactor, system and method provide surface density control which enables the selective formation of varying Si wt.% on the carbon powders.
  • the higher BET surface area graphite powders combined with the use of Cu 2 O catalysts enable uniform Si nanowires growth of 35 wt. % or more of Si as the Si nanowire surface density (simply, Si%/m 2 ) on the substrate surface can be controlled on a suitable graphite substrate having BET surface area in the range of about 1 - 30 m 2 /g.
  • the number of Si nanowires per square meter of the substrate surface will be similar.
  • the inventors have first discovered such surface density control, which enables 32% Si anode material to be cycled in the cells as well as 8% Si anode material, because the volume expansion of Si nanowires during lithiation can be accommodated by more void spaces among the graphite particles in the anode composite layer.
  • embodiments of the present application are shown illustrating the inventive tumbler reactor and chemical vapor deposition (CVD) system configured to grow silicon nanowires on graphite or carbon-based powders in scaled up quantities.
  • CVD chemical vapor deposition
  • a low-pressure CVD (LPCVD) system 100 is shown, generally comprised of an elongated CVD chamber 102, process tube 104 and tumbler reactor 106.
  • the CVD chamber 102 includes heating elements 108 and 110, respectively, which are typically controlled by a processor 128 to heat and cool the process tube 104 and tumbler reactor 106 according to a particular process recipe.
  • the process tube 104 is an elongated cylindrical tube formed of quartz and is positioned inside of the CVD chamber 102. During operation, the process tube 104 is maintained under vacuum. Purge gas, typically nitrogen, is injected into the process tube by vacuum port 112, and an exhaust port 114 connected to a vacuum pump and a cyclone (not shown) is provided at the output end of the process tube 104 to provide the low pressure environment.
  • Purge gas typically nitrogen
  • Tumbler reactor 106 is comprised of an elongated, cylindrical metal chamber and is positioned inside of the process tube 104.
  • the tumbler reactor 106 is configured to rotate inside of the process tube.
  • An electric motor 120 drives the rotation of tumbler 106 via rotation gear 115.
  • Tumbler reactor 106 includes a gas manifold 116 for injecting process gases into the reactor. Any suitable silicon containing process gas may be injected through gas manifold 116. In some embodiments, silane in combination with one or more inert gases, such as nitrogen, helium, argon, and/or hydrogen is injected into tumbler reactor 106 through gas manifold 116. In some embodiments, gas manifold 116 is comprised of a single elongated gas injection member 117 that extends at least a portion of, or the substantial length of tumbler reactor 106. In some embodiments, a plurality of injection ports 119 are positioned along the gas injection member 117 to inject process gases into tumbler reactor 106.
  • the injection ports are substantially equally distributed along the gas injection member to provide substantially uniform distribution of the process gas within the tumbler reactor.
  • the gas injection member 117 is stationary. Alternatively, the gas injection member 117 may rotate. Some process gases are injected into the tumbler reactor 106 by gas purge line 112.
  • tumbler reactor 106 further includes one or more scrapers 113.
  • Scraper 113 is configured to scrap at least a portion of the inner walls of tumbler reactor 106 to prevent build-up of powder on the inner walls.
  • scraper 113 is positioned at one or more of the ends of the tumbler reactor and scraps powder from the periphery of the tumbler reactor.
  • scraper 113 may be comprised of an elongated blade that extends at least a portion of, or the substantial length of the tumbler reactor 106 to scrap powder buildup along the inner wall.
  • scraper 113 may be integrated with gas manifold 116.
  • scraper 113 is attached to the gas injection member 117 by attachment members 121a and 121b which are secured to the feedthrough of flanges 122a and 122b disposed at opposite ends of gas injection member 117.
  • the flanges may be fixed and vacuum-tightened, and thus the scraper 113 will likewise be stationary.
  • the tumbler reactor 106 rotates while the scraper stays stationary.
  • scraper 113 may be configured to rotate.
  • scraper 113 is comprised of an elongated blade 124, the outer side of which scraps powder from the inner wall of the tumbler reactor 106 during tumbler rotation.
  • the elongated blade 124 may include a brush-like member 125 positioned along a portion or the substantial length of the outer side of blade 124, such that the brush-like member 125 scraps powder from the inner wall of the tumbler reactor 106 during tumbler rotation.
  • FIG. 2A illustrates another embodiment of a low-pressure CVD (LPCVD) system 200, and is generally comprised of an elongated CVD chamber 202, process tube 204 and tumbler reactor 206.
  • the CVD chamber 202 includes heating elements 208 and 210, which are controlled by a processor 228 to heat the CVD chamber according to a particular process recipe.
  • the process tube 204 is an elongated cylindrical tube formed of metal.
  • the process tube 204 is evacuated by purge gas via port 212 to provide a low-pressure environment.
  • the process tube 206 is exhausted by exhaust port 214 positioned at the output Docket No.: 074214-045100 3 end of the process tube 204 and connected to a vacuum pump and a cyclone (not shown).
  • the tumbler reactor 206 is configured to rotate inside of the process tube 204.
  • An electric motor 220 drives the rotation of tumbler reactor 206 via rotation gear 215.
  • LPCVD system 200 is adapted to provide faster cooling and heating of the process tube 204 and tumbler reactor 206.
  • the tumbler reactor 206 is configured to be removed from the CVD chamber 202.
  • the tumbler reactor 206 and process tube 204 may be removed from the CVD chamber 202 once the process is complete, and then allowed to cool, while another tumbler reactor and process tube are placed into the process tube and CVD chamber.
  • This configuration allows for faster processing since the CVD chamber does not need to be cooled and then heated for each batch, thereby increasing utilization efficiency of the system.
  • CVD system 200 further includes a carriage rail 221 with wheels 222 that is configured to slide the tumbler reactor 206 in and out of the process tube 204 and to support the tumbler reactor 206.
  • the carriage rail allows the tumbler reactor 206 to move in and out of the metal process tube 204.
  • the carriage rail also supports the tumbler reactor 206 when it is heavy with powders.
  • a metal process tube 204 is used, thereby replacing a quartz process tube, to enable loading of heavier powder material into the tumbler reactor 206, which provides increases Si nanowire production volume.
  • the tumbler reactor 206 and process tube 204 are configured to slide in and out of the CVD chamber 202.
  • Tumbler reactor 206 includes a gas manifold 216 for injecting process gases into the reactor.
  • gas manifold 216 is comprised of a single elongated gas injection member that extends the substantial length of tumbler reactor 206.
  • the gas manifold is comprised of a U-shaped gas injection member 217.
  • a plurality of injection ports 219 are positioned along the U-shaped gas injection member 217 to inject process gases into tumbler reactor 206.
  • the injection ports are substantially equally distributed along the gas injection member to provide substantially uniform distribution of the process gas within the tumbler reactor.
  • the U-shaped gas injection member 217 is stationary. Alternatively, the U-shaped gas injection member 217 may rotate.
  • the tumbler reactor 206 may further include one or more scrapers 213 as described above with respect to FIG. 1 .
  • Scraper 213 is configured to scrap at least a portion of the inner walls of tumbler reactor 206 to prevent build-up of powder on the inner walls.
  • the scraper 213 is positioned at one or both of the ends of the tumbler reactor and scraps powder from the periphery.
  • scraper 213 may be comprised of an elongated blade that extends the substantial length of the tumbler reactor 206 to scrap powder buildup along the inner wall.
  • scraper 213 may be integrated with U-shaped gas manifold 216.
  • the scraper 213 is attached to the gas injection member 217 by attachment members 223a and 223b secured to opposite ends of U-shaped gas injection member 217.
  • the tumbler reactor 206 rotates while the U-shaped gas injection member 217 and scraper 213 stay fixed.
  • U-shaped gas injection member and scraper may be configured to rotate.
  • scraper 213 is comprised of an elongated blade 224 with a brush-like member 225 positioned along a portion or the substantial length of the outer side of blade 224, such that the brush-like member 225 scraps powder from the inner wall of the tumbler reactor 206 during rotation.
  • FIG. 2B An alternative embodiment is illustrated in FIG. 2B , wherein to increase throughput and reduce process time between cycles, the CVD chamber 202 is moved away from the process tube 204 and tumbler reactor 206, as shown generally by the direction of the arrow in Fig. 2B .
  • CVD chamber 202 with its heating elements 108, 110 is pulled away from the tumbler reactor 206 and process tube 204 once the process is complete, and thus may then receive another tumbler reactor and process tube for more processing.
  • This configuration allows for faster processing since the CVD chamber does not need to be cooled and then heated for each batch, thereby increasing utilization efficiency of the system.
  • a carriage rail 226 with wheels 227 are positioned to carry and slide the CVD chamber 202 away from the process tube 204 and tumbler reactor 206.
  • FIG. 3A illustrates a partial cross-sectional view of exemplary tumbler reactor 300
  • Figs. 3B and 3C shows partial end views of tumbler reactor 300
  • FIG. 3D shows a partial bottom cut-away view of tumbler reactor 300
  • tumbler reactor 300 is comprised of an elongated cylindrical tube 303, having first 301 and second 302 ends. Both ends 301 and 302 are generally comprised of a mesh end cap 304 and end plate 306.
  • End plate 306 has a toothed outer edge 305 that extends the entire periphery of the end plate 306 which serves as a gear to rotate the tumbler reactor 300 (for simplicity only a portion of the toothed outer edge is illustrated in the figures).
  • the outer gear 305 engages smaller rotation gear 115, 215 ( FIGs. 1 , 2A and 2B ), coupled to motor 120 to drive the rotation the tumbler reactor 300.
  • a frame 308 ( FIG. 3B ) may be provided for securing the mesh end cap and the end plate via attachment bolts 307.
  • Frame 308 includes apertures configured to receive various components, such as for example the injection manifold 116, 216.
  • mesh end cap 304 is comprised of a mesh having a plurality of apertures 309 which are sized to allow flow of the process, purge and other gases between the tumbler reactor and the process tube, while containing the graphite powder inside the tumbler reactor and prohibiting the flow of any graphite powder into the process tube.
  • the size of the mesh apertures 309 in the mesh end cap 304 can vary depending on the size and/or shape of the graphite powder loaded into the tumbler reactor 300.
  • the mesh end cap 304 enables uniform gas distribution from the gas manifold to the graphite powder inside the tumbler reactor.
  • Tumbler reactor 400 includes one or more fins 402 mounted or formed on one or more inner walls 404 of the tumbler reactor 400.
  • the fins 402 are of any suitable size, shape or distribution and are configured to provide control and/or distribution of the powder motion in the tumbler reactor, particularly during injection of process gases.
  • the fins 402 are configured to prevent the graphite or carbon-based powder from slipping along or clinging to the walls during rotation of the tumbler reactor. The fins may also assist in lifting the loaded graphite powders as the tumbler reactor rotates.
  • the fins 402 are an elongated lip that projects from the surface of the inner wall.
  • the height of the fins 402 may vary depending on the type of graphite powder used, among other factors. In some embodiments, the height of the fins 402 are in the range of about 0.05 to 50mm. The height of each of the fins 402 may be uniform, alternatively the height of one or more of the fins 402 may vary.
  • the fins 402 may have a rectangular shape as shown in FIG. 4A , or a triangular shape as shown in FIG. 4B , among other shapes.
  • the fins 402 have a curved shape which assists in lifting the graphite powder as the tumbler reactor rotates.
  • Those of ordinary skill in the art will recognize that many different shapes may be used, all within the spirit and scope of the present invention.
  • a CVD system 500 is disclosed comprised of two or more tumbler reactors 503a and 503b as illustrated in FIG. 5 .
  • the tumbler reactors 503a and 503b are coupled via flanges 504, and are rotated together by a rotating gear 506 coupled to rotating electric motor 508.
  • the tumbler reactors 503a and 503b may be independent.
  • Process gas in this example silane or silane with a mixture with other gases, such as N 2 , Ar, H 2 or He
  • Process gas is injected into each of the tumbler reactors independently through ports 501.
  • the tumbler reactor rotates inside the process tube and CVD chamber and mixes pre-treated graphite powder loaded in the tumbler reactor while a process gas such as silane (SiH 4 ) is injected into the tumbler reactor under controlled pressure and temperature to ensure the proper condition to grow Si nanowires on the graphite powder.
  • a process gas such as silane (SiH 4 ) is injected into the tumbler reactor under controlled pressure and temperature to ensure the proper condition to grow Si nanowires on the graphite powder.
  • FIG. 6 illustrates a high-level process flow diagram 600 overview of the manufacturing process to Si nanowires according to embodiments of the present application.
  • the tumbler reactor is loaded with graphite or carbon powder pre-treated with catalyst particles (Au or Cu or Cu oxides) deposited on it, and weighed at step 602.
  • the tumbler reactor is inserted into the process tube and CVD chamber where the tumbler reactor and process tube are heated to a specific temperature at step 604.
  • Si nanowires are grown by chemical vapor deposition at step 606. After silicon nanowire growth, the tumbler is removed from the CVD chamber and cooled at step 608.
  • the formed graphite powder with Si nanowires is unloaded at step 610.
  • FIG. 7 illustrates a cross-sectional partial view of an alternative embodiment of a LPCVD system 700 wherein three tumblers 706a, 706b and 706c are processed in a semi-continuous manufacturing process.
  • Each tumbler reactor is loaded with graphite powders with catalysts deposited on the graphite and the tumbler reactor is inserted on one end of the LPCVD system and extracted on the opposite end of the LPCVD system after being processed through a sequence of three active zones, comprised of a heating zone 701, a reaction zone 703, and a cooling zone 705.
  • the three active zones are separated from each other by two buffer zones 702 and 704 which allow the transition of each tumbler from an active zone to the next under controlled conditions of pressure and temperature.
  • the tumbler 706a is heated to reach specific temperature and pressure conditions before moving to the reaction zone 703 through the buffer zone 702.
  • the graphite powder contained in the tumbler reactor 706b mix with the silicon-containing process gas(es) to grow silicon nanowires on the graphite powder, before transitioning to the cooling zone 705.
  • the carbon-based silicon nanowire composite powder contained in the tumbler 706c is cooled down before extracting the tumbler to unload the powder.
  • This configuration ensures a semi-continuous manufacturing process where three tumblers are always present in each of the three active zones 701, 703 and 705 at any moment in time.
  • the advantage of this configuration is that the reaction zone 703 is continuously growing nanowires in a tumbler with no interruption, except for the periodic transition of the tumblers from one active zone to the next.
  • the configuration can be expanded to include N active zones separated from each other through N-1 buffer zones, where N is greater than 3.
  • FIG. 8 illustrates a cross sectional partial view of an alternative embodiment of a LPCVD system 800 wherein the tumbler reactor comprises a helicoidal chamber 802 configured for continuous manufacturing process.
  • the tumbler reactor comprises a helicoidal chamber 802 configured for continuous manufacturing process.
  • a rotating helix or auger pushes the substrate powder material forward through a sequence of one or more heating zones, reaction zones and cooling zones where the injection of process gases is directed toward the reaction zones where silane is converted into silicon nanowires.
  • LPCDV system 800 includes an elongated CVD chamber 802 which is comprised of at least one preheating zone 804, reaction zone 806 and cooling zone 808, and a gas manifold 801 for injecting process gases (and optionally other gases) into CVD chamber 802.
  • the chamber 802 is maintained under vacuum.
  • Purge gas typically nitrogen, is injected into the chamber by vacuum port 810, and an exhaust port 812 connected to a cyclone (not shown) is provided at the output end of the chamber 802 to provide the low pressure environment.
  • the gas manifold 801 is comprised of an elongated gas injection member 814 that extends through the substantial or entire length of the chamber 802.
  • the gas injection member 814 contains a plurality of injection ports 815 along a section of the gas injection member 814 that is positioned in the reaction zone 806.
  • the injection of process gases in the reaction zone 806 (generally silane, optionally mixed with one or more inert gases such as nitrogen, argon, helium and/or hydrogen) convert silane into silicon nanowires grown on the graphite powder.
  • the sections of the gas injection member 814 that are positioned in the preheating 804 and cooling zones 808 do not contain ports and thus process gases are not injected into these zones.
  • Graphite powder is loaded into the chamber 802 by graphite injector 816.
  • the graphite powder has been pretreated to deposit catalysts on the graphite powder.
  • a rotating helix or auger 803 pushes the graphite powder forward through the preheating zone 804, reaction zone 806, and cooling zone 808.
  • the auger 803 may be integrated with the gas injection member 814, or alternatively may be separate from the gas injection member 814.
  • a gas conduit is formed through the center of the auger for radially distributing the gases.
  • a scraper as described above can be included in one or more of the zones 804, 806, 808 to minimize buildup of powder on the inner walls of the chamber 802.
  • the graphite powder As the graphite powder enters the chamber 802, the graphite powder is dried under vacuum and preheated in preheating zone 804. As the graphite powder travels through the preheating zone, the graphite is heated to a specified temperate. The heated graphite powder then exits the preheating zone and enters the reaction zone. Optionally, the preheating and reaction zones may be separated by purge or isolation curtains (not shown) or other suitable means to partially or fully isolate the zones. As the heated graphite powder enters and travels through the reaction zone 806, the graphite powder mixes with the silicon-containing process gas(es) to grow silicon nanowires on the graphite powder to form a carbon-based silicon nanowire composite powder. Next, this silicon nanowire graphite powder travels through the cooling zone 808 where the powder is cooled. Once the powder (now the formed product) passes through the cooling zone 808, the powder is removed continuously from the chamber 802 via product output 818.
  • the graphite powder moves through the multiple zones by helical movement driven by the auger 803.
  • Each of the zones 804, 806, 808 may require a different residence or travel time, depending on the processing step being carried out in each zone.
  • preheating of the graphite powder in the preheating zone 804 may require more time than the time needed to grow the silicon nanowires in the reaction zone 806.
  • control of the residence or travel time though a particular zone is achieved by varying the pitch of the auger 803 in that zone, as represented in FIG. 8 which shows three auger sections 1, 2 and 3.
  • the pitch of the auger may be adjusted to be narrower or wider, depending on the need.
  • the speed of travel of the graphite powder through each zone may be selectively tuned. While the three auger sections illustrated in FIG. 8 are similar in length, this is solely for simplicity and it will be understood that the length of the various auger sections may vary according to the teaching of the present invention.
  • a semi-continuous batch system and process are provided, which enable multiple tumbler reactors to be processed in a semi-continuous manner.
  • the process tube is elongated and configured to accommodate four tumbler reactors for example, with heating, reaction (growing) and cooling zones such that multiple tumbler reactors may undergo processing and move from zone to zone through the process tube, which allows tumblers to be loaded and unloaded at each end of the process tube in a semi-continuous manner.
  • the methods, systems and reactors uses to produce the carbon-based silicon nanowire composite powders describe above, are further processed to form an anode.
  • the anode is formed by coating an electrode foil with the carbon-based silicon nanowire composite powders according to coating techniques known in the art.
  • the anode is further combined with a cathode, a separator and an electrolyte to form a lithium ion battery.
  • the apparatus and methods described herein provide significant advantages over prior manufacturing techniques, and the increased production volume provided by the apparatus and system of the present application will help enable and promote the widespread adoption of Si nanowires grown on graphite or other carbon powders as anode materials in the battery industry.

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US11728477B2 (en) 2016-07-15 2023-08-15 Oned Material, Inc. Manufacturing apparatus and method for making silicon nanowires on carbon based powders for use in batteries
CN112599758A (zh) * 2021-03-03 2021-04-02 拓米(成都)应用技术研究院有限公司 纳米硅团聚体复合负极材料及其制备方法

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US20240162426A1 (en) 2024-05-16
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US20180019468A1 (en) 2018-01-18
US20230352668A1 (en) 2023-11-02
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EP3484810A2 (de) 2019-05-22
WO2018013991A3 (en) 2018-02-22
KR20190030723A (ko) 2019-03-22
EP3778471B1 (de) 2022-04-20
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CN109689567A (zh) 2019-04-26
US10862114B2 (en) 2020-12-08
WO2018013991A2 (en) 2018-01-18
CN109689567B (zh) 2022-09-09
US20180019467A1 (en) 2018-01-18
DK3484810T3 (da) 2023-11-20
EP3484810A4 (de) 2020-03-25
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